Saudi Aramco 2616-ENG (10/2002)

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SAUDI ARABIAN OIL COMPANY

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DISCIPLINE
ENGINEER

DRD

DATE J UN-12
PROJ ECT
ENGINEER

________________

DATE ___________
CERTIFIED

RS

DATE ___________
CONSTRUCTION
AGENCY

________________

DATE ___________
OPERATIONS


________

DATE ___________

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_
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MECHANICAL RERATE REPORT FOR DWG.TYPE
PLANT .NO INDEX DRAWING NO. SHT. NO.
REV.
NO.
HIGH PRESSURE SEPERATOR (R215-V6) DOC
Z12 D PP-E05448
52
OF
71
B
CLEAN TRANSPORTATION FUELS PROJ ECT, RIYADH REFINERY
RIYADH, SAUDI ARABIA J O / EWO: BI-10-00741
DOC CLASS: 4 DSN: 2179
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.



APPENDIX 3 PRELIMINARY SAFETY INSTRUCTION SHEET


psi
I.D. m(ft) Nom. Thick. mm(ins SHAPE
3 mm(in)
EQUIPMENT DATA
3 mm(in)
32-SAMMSS-004
FYC-Z12-32-A039-001-001
ASME VIII DIV 2 1977 Ed, API 510 9TH Ed 2006
; CORROSION ALLOWANCE
SERVICE
SA 266 Cl 2
HGH PRESSURE SEPARATOR
HEAD I.D. m(ft.)
ORDER NO.
; CORROSION ALLOWANCE
LENGTH m(ft.)
55 BOOT
3.98
0.91
BUTT (SINGLE SIDED GROOVE) SHELL TO HEAD
HEAD FULL BUTT (DOUBLE SIDED GROOVE)
SEAMS TYPE RADIOGRAPHY EFFICIENCY E
225
O
C(
O
F)
7.62
1.67
3.98
: RATING AND FACING
1500#RTJ
1500#RTJ / RF
POSITION kPa (psi) POSITION
: THICK, MAT'L. AND
LIMITED BY :
LINING
PACKING
TRAYS
BOTH
MDMT:
0.85 / 1.0 POST WELD HEAT TREATMENT
YES (TBC)
AT TOP
SHELL STRESS
232
2904
kPa (psi)
PROTECTED BY SAFETY VALVE ON
TEST PRESSURE, at TOP
103.4 EXTERNAL PRESSURE :
S.V. SET AT
MINIMUM THICKNESS
HEADS :
PRESSURE AND TEMPERATURE 47.8
OTHER GOVERNING CONSIDERATION
SHELL SECTION tm mm(ins)
DRAWING NO.
BASED ON :
INDEX
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RIYADH REFINERY
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NOTES:
1. CORROSION ALLOWANCE HAS BEEN REVISED TO 3MM FROM ORGINAL 4.8MM. NO BENEFIT FROM THIS CHANGE HAS BEEN ASSUMED TO CONTRIBUTE
TO MATERIAL PRESSURE THICKNESS, THE EXCESS HAS BEEN ASSUMED TO COVER ANY MATERIAL LOSS FROM OPERATION.
2. CALCULATED TEST PRESSURE INDICATED IS AS A RESULT OF THE RERATE TO 232C DESIGN TEMPERATURE AND MUST BE CARRIED OUT IN THE
FIELD.
BOTH 101.4 INDICATED DESIGN TEMP AND PRESSURE
: THICK AND TYPE
BASED ON INDICATED DESIGN
: NO. MAT'L. AND DRAWING NO.
: SHOP
: SIZE, HEIGHT AND MAT'L.
METHOD OF ATTACHMENT
kPa (psi) FIELD
SHELL
SPECIAL DESIGN CONSIDERATION OR
UNUSUAL CONSTRUCTION FEATURES
kPa (psi)
OPERATING LIMITS
(CHANGES TO OPERATING LIMITS REQUIRE OPERATIONS ENGINEERING APPROVAL)
14514 DESIGN PRESSURE, AT TOP
O
C(
O
F)
SHELL
INDICATED DESIGN TEMP AND PRESSURE
20030 (Note 2)
TEST PRESSURE, WIND LOAD, OR
DWG. TYPE
: RATING AND FACING
INDICATED DESIGN TEMP AND PRESSURE
SIS
220.2
BOOT
NOTE BELOW ANY SPECIAL HAZARDS, RECOMMENDATIONS, INSPECTIONS, OR TESTS THAT ARE IMPORTANT FOR THIS EQUIPMENT.
1 OF 1
PLANT NO.
A
SHT.NO. REV.NO SIS FOR
SAFETY PRECAUTIONS
CALCULATED TEST PRESSURE
O
C(
O
F)
kPa(g) (psi) @
TESTS NEW
AMB
APPLICABLE CODE AND EDITION
N/A
HEMISPERICAL
19123 HORIZ
kPa (psi)
MANWAY
NOZZLE
J
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BUTT (SINGLE SIDED GROOVE)
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SPEC'N NO.
HORIZONTAL
1977
RU822M0008
CONCRETE LINED BOTTOM HALF OF VESSEL AND BOOT, BOTTOM NOZZLES MONEL LINED
KOBE STEEL LTD
SHELL
ASSEMBLY DRAWING
110
N/A
INSULATION
A Z12
1.0
1.0
HYDROCRACKER UNIT (Z12)
HIGH PRESSURE SEPARATOR
Nom. Thick. mm(ins)
Saudi Aramco 2694-ENG (11/2010)
SAUDI ARABIA RIYADH,
EKRD/2694-1110.XLS
R215-V6 NO.
POSITION
DESIGN SHEET NO.
HEADS
R215-V6
MANUFACTURER
SHELL SECTION
SAUDI ARABIAN OIL COMPANY
DATA AND OPERATING LIMITS SHEET - PRESSURE VESSELS
Z12-D-PP-E01204
MANUFACTURER'S SERIAL NO.
EQUIPMENT NO.
MATERIAL SPECIFICATION SA 516 Gr 70
YEAR BUILT
MATERIAL SPECIFICATION
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SPOT FULL
PARTIAL FULL
YES NO
Saudi Aramco 2616-ENG (10/2002)
O
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N
S

SAUDI ARABIAN OIL COMPANY

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DISCIPLINE
ENGINEER

DRD

DATE J UN-12
PROJ ECT
ENGINEER

________________

DATE ___________
CERTIFIED

RS

DATE ___________
CONSTRUCTION
AGENCY

________________

DATE ___________
OPERATIONS


________

DATE ___________

E
D
S
D

V
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F
I
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A
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O
N



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:

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_
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/
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(
D
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)
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.

_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_


MECHANICAL RERATE REPORT FOR DWG.TYPE
PLANT .NO INDEX DRAWING NO. SHT. NO.
REV.
NO.
HIGH PRESSURE SEPERATOR (R215-V6) DOC
Z12 D PP-E05448
54
OF
71
B
CLEAN TRANSPORTATION FUELS PROJ ECT, RIYADH REFINERY
RIYADH, SAUDI ARABIA J O / EWO: BI-10-00741
DOC CLASS: 4 DSN: 2179
T
H
I
S

D
R
A
W
I
N
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A
N
D

T
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I
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N
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C
O
N
S
E
N
T

O
F

I
T
S

O
W
N
E
R
.



APPENDIX 4 EXTRACTS FROM ASME II D MATERIAL PROPERTIES

Saudi Aramco 2616-ENG (10/2002)
O
P
R
N
S

SAUDI ARABIAN OIL COMPANY

P
M
T


C
E
R
T


E
N
G

G


D
E
S
C
R
I
P
T
I
O
N


I
S
S
U
E
D

F
O
R


C
O
M
M
E
N
T
S

(
F
W
S

R
E
V

O
1
)


I
S
S
U
E
D

F
O
R


P
R
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E
C
T

P
R
O
P
O
S
A
L
(
F
W
S

R
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V

D
1
)


J
O
/
E
W
O

1
0
-
0
0
7
4
1

1
0
-
0
0
7
4
1


D
A
T
E

F
E
B
-
1
2

J
U
N
-
1
2


R
E
V
.

N
O
.

A

B


DISCIPLINE
ENGINEER

DRD

DATE J UN-12
PROJ ECT
ENGINEER

________________

DATE ___________
CERTIFIED

RS

DATE ___________
CONSTRUCTION
AGENCY

________________

DATE ___________
OPERATIONS


________

DATE ___________

E
D
S
D

V
E
R
I
F
I
C
A
T
I
O
N



C
O
N
T
R
O
L

N
U
M
B
E
R


B
Y
:

_
_
_
_
_
_
_
_
_
_
_
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_


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A
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E

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_
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.

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.

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,

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A
P
P
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/
C
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F
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N

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S
,

B
Y

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N

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A
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(
D
C
C
)
N
O
.

_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_


MECHANICAL RERATE REPORT FOR DWG.TYPE
PLANT .NO INDEX DRAWING NO. SHT. NO.
REV.
NO.
HIGH PRESSURE SEPERATOR (R215-V6) DOC
Z12 D PP-E05448
59
OF
71
B
CLEAN TRANSPORTATION FUELS PROJ ECT, RIYADH REFINERY
RIYADH, SAUDI ARABIA J O / EWO: BI-10-00741
DOC CLASS: 4 DSN: 2179
T
H
I
S

D
R
A
W
I
N
G

A
N
D

T
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E

I
N
F
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M
A
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I
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N

C
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T
A
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D

H
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D

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N
T

W
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T
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W
R
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T
T
E
N

C
O
N
S
E
N
T

O
F

I
T
S

O
W
N
E
R
.



APPENDIX 5 FWS STANDARD MINIMUM NOZZLE LOADS

Extract from FWS Standard Nozzle Loads for 1500# Process Nozzles
F
x
F
y
F
z
M
x
M
y
M
z
Nozzle Size (inch), D = 4 4.0 4.0 5.6 1.9 1.9 2.6
10 10.8 10.8 15.2 11.3 11.3 15.9
12 13.5 13.5 19.2 16.4 16.4 23.3
16 19.4 19.4 27.6 29.4 29.4 41.4
Direct Loads (kN) Moment Loads (kNm)
Saudi Aramco 2616-ENG (10/2002)
O
P
R
N
S

SAUDI ARABIAN OIL COMPANY

P
M
T


C
E
R
T


E
N
G

G


D
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S
C
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P
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I
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N


I
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D

F
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C
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S

(
F
W
S

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V

O
1
)


I
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D

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P
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T

P
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(
F
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D
1
)


J
O
/
E
W
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1
0
-
0
0
7
4
1

1
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-
0
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7
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1


D
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-
1
2

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-
1
2


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V
.

N
O
.

A

B


DISCIPLINE
ENGINEER

DRD

DATE J UN-12
PROJ ECT
ENGINEER

________________

DATE ___________
CERTIFIED

RS

DATE ___________
CONSTRUCTION
AGENCY

________________

DATE ___________
OPERATIONS


________

DATE ___________

E
D
S
D

V
E
R
I
F
I
C
A
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I
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N



C
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B
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:

_
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_
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(
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_
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_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_


MECHANICAL RERATE REPORT FOR DWG.TYPE
PLANT .NO INDEX DRAWING NO. SHT. NO.
REV.
NO.
HIGH PRESSURE SEPERATOR (R215-V6) DOC
Z12 D PP-E05448
61
OF
71
B
CLEAN TRANSPORTATION FUELS PROJ ECT, RIYADH REFINERY
RIYADH, SAUDI ARABIA J O / EWO: BI-10-00741
DOC CLASS: 4 DSN: 2179
T
H
I
S

D
R
A
W
I
N
G

A
N
D

T
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I
N
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.


N
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C
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N
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N
T

O
F

I
T
S

O
W
N
E
R
.


APPENDIX 6 INSPECTION REPORTS

RIYADH REFINERY DEPARTMENT
ENGINEERING DIVISION
INSPECTION UNIT
2009, TRS INSPECTION FINAL REPORT
2009
Field Insp. Supervisor:
M. Banammahl M.RALAL
4.8mm
177 .C
03/23/2009
Plant No.:
2-12
Date prepared:
Locationl Area:
G-H drocracker
Date Inspected:
110/2009
Unit Supervisor:
Yahya, Kh Ii
Corrosion Allowance
Design Press.
Design Temp.
Claddingl Lining
E ui ment data:
Material
Report No.: INSP G/021/09
Equipment No. & Service:
215-V-6 Se arator
Reasonfor Inspection:
TRS, March/Februa
P&E Inspector:
Greg Jolley API #5184
Thick.
Inspection summary:
A full internal and external visual inspection was performed per API-510 and Aramco
guidelines, during the February 2009 plant wide T&1. A scaffold was erected for full
access. The bottom half is concrete lined. Civil required minimal repairs. The top half
was grit blasted for WFMP on the welds with no relevant indications. A new demister
was installed. The top unlined portion of the vessel has mild corrosion .030" (. nOmm)
shell and .060" (1.54mm) nozzles. Corrosion in the manway RTJ "0" ring will require
repairs next scheduled T&1.
Observations:
There was 3" of product sludge found in the bottom prior to cleaning. The vertical wall
demister was removed and replaced with like kind 316ss, double wired down and
visually accepted. The support ring was securely attached by to the shell with no visible
cracking or corrosion noted. This demister was moderately fouled with scale and
product. Previous process changes eliminated the use of the outlet gas demister. A full
scaffold was erected for access. The bottom half is concrete lined with minor repairs.
The boot section was also lined. Minor repairs were required (see civil for iining issues).
The top half had a scattered thin hard scale. Corrosion in the top half is generally .030"
(.770mm) with isolated pitting in the middle top section to .040" (.1OOmm). The welds are
in the same condition as the adjacent base metal with no visual defects. Nozzles were
clear and free of obstruction. General corrosion in the nozzles 10 was .040" (.700mm)
and isolated pitting in the top nozzles to .060" (.150mm). The inlet distributor was clear
with no corrosion. The slots were full thickness. There were 2 of the 3 hold down
bolts/nuts missing. These were replaced with like kind and accepted. The liquid outlet
stand pipe was intact and secure with no corrosion or erosion. The bottom outlet nozzle
was flushed free of any loose hardware and debris. The top gas outlet nozzle (12") and
manway RTJ "0" rings and seats were PT tested and had no corrosion. The top manway
and cover has moderate corrosion on the RTJ "0" ring seating surface and is
738
Only head material
SA 516 Gr. 70.
Shell, boot, nozzles
SA 266 Cl2
148 kg/cm
2

recommended to weld build up and machine next scheduled T&1. The top half of the
shell welds were grit blasted for WFMP with no relevant indications reported. This vessel
is fit for continued service until the next T&1.
Refractory lining:
The bottom half is concrete lined with minor repairs. The boot section was also lined.
Minor repairs were done and accepted by civil inspector.
RepairsIT ests:
1. Minor concrete lining repairs were made per the civil recommendations.
2. UT scanning the bottom external performed on the shell with no issues reported.
3. UT thickness was performed with no measureable wall loss noted.
4. WFMP was performed on the top welds after grit blasting with no indications
noted.
5. A new vertical wall demister was installed.
6. The top gas outlet was lifted and the RTJ "0" ring and seats PT tested with no
indications or corrosion
Future Recommendations:
1. Open, clean and Inspect during the next scheduled T&I,March 2013
2. Flush with firewater to remove sludge
3. Build full scaffold for access to the top head
4. Grit blast the top section welds for WFMP(grit blasting was performed this T&I
because wire brushing would not remove the hard scale)
5. Flush outlet piping after all work is completed, break outside flange and gap
minimum 30mm to flush loose nuts and bolts
6. Weld build up the manway gasket surfaces and machine (both head and cover)
due to corrosion on the seats.
7. Install new demister pads
8. Remove support rings on gas outlet nozzle for inspection and NOT.
9. Open water boot and offer for inspection.
10. Remove bottom insulation for UT
11. Straight beam scan to check thickness under cement lining.
12. Provide 110/220 power cable for WFMPI
cc:
Area (G) foremen
T&I Supervisor
Equipment File
739
T
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=

F
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T
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n

s
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t

a
t

0
Saudi Aramco 2616-ENG (10/2002)
O
P
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N
S

SAUDI ARABIAN OIL COMPANY

P
M
T


C
E
R
T


E
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G


D
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I
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C
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(
F
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1
)


I
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P
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R
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.

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.

A

B


DISCIPLINE
ENGINEER

DRD

DATE J UN-12
PROJ ECT
ENGINEER

________________

DATE ___________
CERTIFIED

RS

DATE ___________
CONSTRUCTION
AGENCY

________________

DATE ___________
OPERATIONS


________

DATE ___________

E
D
S
D

V
E
R
I
F
I
C
A
T
I
O
N



C
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N
T
R
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L

N
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B
E
R


B
Y
:

_
_
_
_
_
_
_
_
_
_
_
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_
_


D
A
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_
_
_
_
_
_
_
_
_
_
_
_
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R
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N
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_
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D
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,

F
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P
P
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/
C
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F
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C
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R
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Q
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M
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B
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C
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N

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A
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(
D
C
C
)
N
O
.

_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_


MECHANICAL RERATE REPORT FOR DWG.TYPE
PLANT .NO INDEX DRAWING NO. SHT. NO.
REV.
NO.
HIGH PRESSURE SEPERATOR (R215-V6) DOC
Z12 D PP-E05448
65
OF
71
B
CLEAN TRANSPORTATION FUELS PROJ ECT, RIYADH REFINERY
RIYADH, SAUDI ARABIA J O / EWO: BI-10-00741
DOC CLASS: 4 DSN: 2179
T
H
I
S

D
R
A
W
I
N
G

A
N
D

T
H
E

I
N
F
O
R
M
A
T
I
O
N

C
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N
T
A
I
N
E
D

H
E
R
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N

A
R
E

T
H
E

S
O
L
E

P
R
O
P
E
R
T
Y

O
F

S
A
U
D
I

A
R
A
M
C
O
.


N
O

R
E
P
R
O
D
U
C
T
I
O
N

I
N

F
U
L
L

O
R

I
N

P
A
R
T

S
H
A
L
L

B
E

O
B
T
A
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N
E
D

F
R
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M

T
H
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S

D
O
C
U
M
E
N
T

W
I
T
H
O
U
T

T
H
E

W
R
I
T
T
E
N

C
O
N
S
E
N
T

O
F

I
T
S

O
W
N
E
R
.



APPENDIX 7 PVELITE OUTPUT (FOR VALIDATION ONLY)